Alexei Volkov
Corrugated roofing is a popular and cost-effective roofing option for sheds, shops, patios, and pergolas. It is lightweight, durable, and easy to install, making it a great choice for DIY enthusiasts. Corrugated plastic roofing, in particular, is a long-lasting and low-maintenance alternative to metal roofing. It is flexible, strong, and can be formed into various shapes and sizes, making it ideal for a variety of applications. In this guide, we will cover the steps and provide expert tips on how to build a corrugated plastic roof, from preparing the roof to installing the panels and ensuring a secure and attractive finish.
| Characteristics | Values |
|---|---|
| Materials | Corrugated plastic, PVC, polycarbonate, bitumen, aluminum, metal |
| Pros | Cost-effective, long-lasting, low maintenance, lightweight, easy to install, durable, flexible, good looks, translucent |
| Cons | Prone to dents and divots, susceptible to leaks |
| Installation tips | Pre-drill holes, use special roofing fasteners, use silicone sealant, overlap sheets, use galvanized nails, use flashing, peak seals, closure strips, edging or finishing components |
| Tools | Ladder, scaffolding, angle grinder, tape measure, galvanized nails, neoprene washers, mastic, corrugated sheet nails, plastic protective caps, corrugated sheet screws, nail gun, fine-toothed saw, scissors, sheers |
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What You'll Learn
Planning and measuring
First, measure the area of your roof using a ladder and a tape measure. This step is essential to determine the dimensions and calculate the number of corrugated sheets you will need. Remember to take into account the overlap between sheets, which should be at least 15 cm in length and a complete corrugation in width. The distance between the battens, which are the supports on which the corrugated sheets are attached, will depend on the angle of inclination of the roof and the material used for the sheets. As a general guideline, a distance of 60 cm between battens is usually sufficient.
Before installing the corrugated sheets, prepare the roof by ensuring proper water drainage. The roof should have a pitch of at least one inch per foot to allow rainwater to drain properly. If your roof has a shallower pitch, consider using additional weatherproofing measures to prevent leaks.
When framing the roof, keep in mind that the spacing between roof trusses should not exceed 24 inches (61 cm), and purlins should be no more than 36 inches (91 cm) apart. You can use wood slats as roof supports, spacing them evenly. For example, you can place 9x 12' long 2x4" wood slats 24" apart.
For a secure and attractive finish, use molding strips on top of the rafters. Combine rounded molding strips on the vertical rafters with corrugated molding strips on the horizontal cross-braces. Attach these moldings using galvanized nails to prevent rusting in case of any leaks.
Finally, pre-drilling holes for fasteners is highly recommended to make the installation process easier. Aim to position the fasteners at the high point of every fourth corrugation. The pre-drilled holes should have a diameter of 8 to 10 millimeters and be 2 millimeters wider than the fasteners to allow for expansion when the roof is exposed to heat. Using a stick with a hole drilled in it as a guide will make creating the holes much simpler.
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Preparing the roof
Firstly, measure the area of your roof using a ladder and a tape measure. This step is essential to determine the number and size of corrugated plastic panels you will need. The panels must overlap by at least 15 cm in length, and the overlap in width should be at least one complete corrugation. Calculate the number of panels required, taking this overlap into account.
Next, you should prepare the roof structure. Pre-cut roof rafters to the desired pitch and nail them into position. The slope of the roof must be at least 10 degrees, which equates to a slope of 17 cm per meter. This slope ensures proper water drainage, and you should also ensure that the roof has a terrain of at least one inch per foot.
Now, you can begin installing the supporting construction. For this, you will need wood slats and roof supports. Secure the wood slats to the horizontal beam using brackets, ensuring even placement. Place your 2x2" wood roof supports on top of the wood slats, spacing them evenly. The exact spacing will depend on the angle of inclination of your roof and the material of your corrugated sheets.
Before attaching the corrugated sheets, it is advisable to install flashing on the eaves of the roof. This will provide an extra layer of protection against the elements. You can also attach plastic closure strips to the wood roof supports, snapping them together as you go. These strips will help ensure that the roof sits properly.
Finally, you are ready to begin attaching the corrugated sheets. Place the first sheet at the bottom right or bottom left of the roof, allowing it to protrude a few centimetres at the bottom and on the side. If your roof has a ridge, attach the first row of sheets on the opposite side and place the ridge piece before continuing. Overlap the sheets by at least 15 cm, and use corrugated sheet nails or screws to secure them in place.
By following these steps, you will have a well-prepared roof that is ready for corrugated plastic panels to be installed.
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Installing supports
First, determine the number of supports you need. For a project with a span of 16 feet, you will require at least four roof supports. These supports should be made of strong and durable material, such as wood. In the example project, eight 2x2-inch wood roof supports were used, spaced evenly with 3.5 feet between each support.
Next, place your roof supports on top of the wood slats, ensuring they are securely attached and level. You can attach these supports to the house using lag bolts if your roof is attached to a building. Ensure that the bolts are long enough to go through the siding and into the framing. For example, you can use 16-foot-long 2x4-inch pieces of wood for the ledger and 12-foot-long 2x4-inch slats spaced 24 inches apart.
Now, you will need to install the plastic closure strips onto the wood roof supports. These strips will help ensure that the roof sits properly. Snap the strips together as you go, lining them up carefully. Screw the strips to the wood at the lower part using decking screws. For example, you can use 1.5-inch decking screws.
Finally, check that all your supports and strips are securely fastened and level before moving on to the next step of installing the corrugated roof panels. Remember to work safely and use a stable ladder or scaffolding when installing your corrugated plastic roof.
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Attaching the panels
Prepare the Roof:
Firstly, ensure your roof has a pitch of at least one inch per foot to allow for proper water drainage. If your roof has a shallower pitch, consider additional weatherproofing measures. Next, install an underlayment and flashing on the eaves of the roof. Flashing will protect the joints of your roof from water damage.
Measure and Cut the Panels:
Measure the roof's dimensions and cut the corrugated panels to size using an angle grinder. The panels must overlap by about 3-4 inches (7.6-10.2 cm) or at least one corrugation. This will ensure a secure fit and help prevent leaks.
Attach the Panels:
Starting from the eaves, attach the first panel, allowing it to protrude a few centimeters at the bottom and on the side. Place the second panel above it, ensuring an overlap of 3-4 inches. Secure the panels with nails or screws. Use corrugated sheet nails or screws specifically designed for roofing, as these have waterproof seals that prevent leaks. Fasten the panels through the crowns at every second or fourth corrugation.
Seal the Joints:
When joining panels, use a generous amount of silicone sealant along their vertical length to ensure there are no gaps. You can also use butyl tape for additional sealing.
Install Peak Caps:
Once all the panels are attached and sealed, install the peak caps on top of the panels. Seal any visible seams with a sealant to ensure a watertight finish.
Remember to work safely and follow local building codes and recommendations. Do not stand or walk on the panels; use ladders or scaffolding instead. Always wear protective gear and follow the manufacturer's instructions for your specific roofing material.
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Sealing and finishing
Corrugated roofing is a great, cost-effective roofing option that is easy to install. It is a popular choice for those looking to save money on professional installation, as it is lightweight and easy to work with.
To seal and finish a corrugated plastic roof, there are several steps to follow. Firstly, it is important to ensure that the roof has a pitch of at least one inch per foot to allow for proper water drainage. If your roof has a shallower pitch, consider using additional weatherproofing measures.
For a secure and attractive finish, use molding strips on top of the rafters. Use corrugated molding strips on the horizontal cross-braces and rounded molding strips on the vertical rafters. Attach the moldings with galvanized nails to prevent rusting in case of any leaks.
When joining panels, use a generous amount of silicone sealant along their vertical length and overlap the sheets by one corrugation. This will ensure that there are no gaps and provide the best performance in terms of waterproofing.
To avoid deflection of panels, tighten screws until washers will not rotate, then tighten them one more turn. This will help to create a secure and sturdy roof.
Finally, you may need to cut the last row of corrugated sheets to size. For added strength, this closing row should consist of at least three corrugations, so a larger overlap may be required. Finish the roof on the ends with bargeboards, which can be made from two waterproof plywood slats screwed at a right angle to each other. This will provide protection against storms.
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Frequently asked questions
Corrugated plastic roofing is a cost-effective, long-lasting, and low-maintenance roofing option. It is lightweight, flexible, and easy to work with, making it a popular choice for DIY projects.
Materials required include corrugated plastic roof panels, wood slats or rafters, galvanized nails or screws, a nail gun or drill, a ladder, and silicone sealant.
First, measure the roof area and cut the panels to size. Prepare the roof by installing flashing and ensuring proper drainage. Attach the panels by overlapping them and securing them with nails or screws. Seal any seams with silicone sealant.
The roof should have a pitch of at least one inch per foot to allow for proper water drainage. If the pitch is shallower, additional weatherproofing measures may be necessary.
Always work from a stable ladder or scaffolding to avoid standing or walking on the panels. Pre-drill holes for fasteners to make installation easier and prevent leaks. Do not drill holes in the valley of the ridges to avoid leaks.
